On to the driver's door today. Didn't break anything this time, but there was plenty of other damage.
It immediately became clear that like the passenger side, someone had been in here before. The first thing I saw was this cracked hot glue repair. More an attempt to fix rattles I think.
It also became obvious this armrest pad was in much worse condition underneath.
At least a few of Humpty Dumpty's pieces are large enough to help in the repair.
As for the large panel, it needed some of the same repairs as the passenger door...a good cleaning, and a good glue repair for the broken plastic spot welds on the big pocket. However, these front door panels are NOISY! I can't get the videos to load, but you would not believe how much noise those small plastic pockets make when the panel flexes. It's crazy. Time to peel back the jute and see what we can do.
When I had to rebuild the plastic radio pod for my T/A, I padded areas that rubbed together with a very thin cloth. I'm going to use the same trick here.
Ready to go back into the panel.
Installed, with a little ribbon of dum dum for good measure.
You'll have to take my word for it since the video won't load....but this made a HUGE difference. Glue the jute back down, the the big panel is done.
Meanwhile, back on the bench...stainless washers are JB Welded into the bottom of the pad, to reinforce the areas of shattered plastic around the screw holes.
Also some weld for the cracked plastic frame.
And lots of epoxy to strengthen the bottom, and the broken plastic pieces.
The rest is pretty much the same as the other door. Tweeter installed, soldered pigtail, carpet around crossover and wiring, old blown driver removed, trimmed speaker opening on panel, previous hot glue repair re-melted, etc. Pad back on the door panel with two stainless sheet metal screws and one small machine screw.
Tomorrow I'll add the sound deadening to the door inner, install the new Alpine driver with Boom Mat baffle, and reassemble the door.